Conductive polymers substituted with acid labile functional groups for increasing electrical conductivity and patternability and composition having the same

ABSTRACT

The present invention relates to a conductive polymer. The present invention provides a conductive polymer substituted with acid labile functional groups including an amine functional group and an acid labile functional group which plays a protecting role substituted to an amine functional group of a conductive polymer. The conductive polymer of the present invention has enhanced physical and mechanical properties with higher solubility and conductivity than a previous polyaniline or polypyrrole composition, and also, has improved transparency, sensitivity, adhesive property and patternability. Moreover, the conductive polymer of the present invention has the higher electrical conductivity of the minimum 10 times and the most maximum 10 2  S/cm than the previous polyaniline, and accordingly, can be used for a photosensitive material such as a fiber, a coating, an electrode, an organic semiconductor, and the like.

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates to conductive polymer, and more particularly it relates to conductive polymers substituted with functional group for increasing electrical conductivity and patternability and Composition having the same.

CONVENTIONAL ART OF THE INVENTION

[0002] Research of conductive polymer was launched in late sixties and conductive polymer began to attract attention by discovering, which adding electron donor or electron acceptor to polyacetylene as it called doping in 1977, the polymer has electrical conductivity in accordance with metal. Its research was applied to various conductive polymers such as polyaniline, polypyrrole, polythiophene, and polyphenylenevinylene and progressed up-to-date.

[0003] Among that, polyaniline may be classified completely reduced from, leuco-emeraldine, partly oxidized form, emeraldine, and completely oxidized form, pernigraniline.

[0004] The polyaniline with emeraldine form has advantage that its electrical property may be adjusted broad range by oxidation state or acid-adhesion of polymer backbone and structural property of dopants and that it is stabilized in air or aqueous solution and has relative inexpensiveness. But, its low insolubility and unmeltability to heat resulted in limiting its processability extremely. Accordingly its commercial use is limited.

[0005] Especially, polyaniline has at least over 1 S/cm (Siemens/cm) of electrical conductivity in order to directly use it as IC or material for shielding from electronic wave. But, to satisfy this condition, it must convert to emeraldine salt form by doping it or add separate oxidizing agent.

[0006] Also, conventional conductive polymers including the polyaniline have insolubility and unmeltability in ordinary organic-solvents and as a result solvents are limited in manufacture of film, compatibility and the like. And to improve electrical conductivity, mechanical property of mater and processability, additives must be added separately. But, these additives are obstacle to manufacture of fine pattern by making aggregates commonly. To overcome this problem, various methods have been suggested.

[0007] In these years the research, with regard to method for reforming the conductive polymer and common polymers into complexes with enhancing electrical conductivity through simple mixing and graft copolymer or derivative synthesis, was reported.

[0008] In related with above contents, the composition, which can hydrogen bond with polyaniline, contains phenol substituent with interaction between rings and organic acid, metal salt and the like for enhancing processability and can be processed in liquid phase, was reported (U.S. Pat. No. 5,520, 852). But, on this composition containing polyaniline over 15% by weight, it became gelation owing to intermolecular hydrogen bond. As a result the composition has disadvantage of being difficult to obtain needed material.

[0009] To overcome the disadvantage, a method for processing conductive polymer comprising adding gel inhibitor such as secondary amine into gelated composition was filed (U.S. Pat. No. 6,099,907 and U.S. Pat. No. 6,123,883). On using gel inhibitors, it is difficult to anticipate stabilizing electrical conductivity (hereinafter referred as conductivity) and it has disadvantage of deteriorating mechanical properties, though.

[0010] Besides, research in which solubility and processibility of conductive polymer can be increased owing to applying di-isooctyl phosphate into the polymer as plasticizer was reported (Laska, J J. Appl. Poly. Sci., Sci., 61: 1339-1343, (1996), Materials Science Forum, 122: 177˜184(1993)). But, this polymer has disadvantage of relatively reducing conductivity resulting from using plasticizers such as di-isooctyl phosphate to increase compatibility with common polymers and solubility of it.

[0011] As another method for enhancing conductivity of conductive polymers, the research with regard to method doping conductive polymers with organic acid dopants such as dodecylbenzenesulfonic acid (hereinafter referred as DBSA), camphorsulfonic acid (hereinafter referred as CSA) having high molecular weight was reported (Heeger Synth. Met., 48, 91 (1992)). And research which described complexes having conductivity can be manufactured was reported. In the research, on exposing light into polypyrrole and complex of polyvinylchloride (PVC), nonconductive material, and FeCl₃ on the substrate, selective exposed FeCl₃ was converted into inert iron salt and as a result only unexposed part was doped by FeCl₃.

[0012] And research which conductivity of polymer can be enhanced at best 0.1 S/cm by exposing triphenylsulfonium hexafluoroantimonate (TPSFPA) as photo-oxygen reagent and polyaniline with nonconductor form and doping the polymer with producing acid was published (Angelopolous “Conducting polymers as Lithographic Materials” Polymer Eng.&Sci., vol. 32, No. 20, pp. 1535˜1540(1992)).

[0013] Recently, the application about polyaniline film assuming patternability and conductivity by exposing polyaniline doped with acid and photo-base reagent to light and exposed selectively by light-induced base was flied (U.S. Pat. No. 6,045,977).

[0014] But FeCl₃ as inorganic component, TPSFPA and photo-induced doping method by photo-base reagent mentioned above has difficulty of compatibility owing to extremely low insolubility with solution of conductive polymers. Besides the polymer has difficulty doping, owing to the conductive polymer's absolving, over some exposed light to lower efficiency of photo-acid production and of making pattern because of slight solubility difference.

[0015] U.S. Pat. Nos. 5,756,601; 5,100,977; 5,237,023; 5,254,670 and 5,250,639 are shown the possibility of conductive polymer applicable to materials for shielding electronic wave and for preventing static electricity by synthesizing polyaniline soluble in organic solvents through a reaction among alkylation, alkoxylation induced from amine functional group of polyaniline. But these polymers have disadvantage of reduced linearity of the backbone of lowered crystallinity and of lowered electrical conductivity extremely resulted from inducing substituents with lower molecular weight into backbone of conductive polymer permanently.

[0016] In another example, research in which conductivity and processability of polymer can be enhanced by synthesizing polyaniline substituted with acid/ thermal labile tert-butyloxycarbonyl(t-BOC) protection group using palladium metal catalyst (Xiao-Xiang et al. J. Am. Chem. Soc. 2000, 122, 7606-7607). But in this research t-BOC group is not substituted polyanilie emeraldine salt composing amine to imine 1:1 ratio, the method needed adding proceedure of 185° C. pyrolysis by oxidizing partly polyaniline of leucoemeraldine form to produce polyaniline emeraldine salt and t-BOC group has linear form prior to prolysis. As a result, it has disadvantage of difficulty maintaining crystallnity or linearity of polyaniline emeraldine salt.

[0017] Accordingly, the polymer synthesized by using palldium metal catalyst may settle the disadvantage of insolubility and unmeltability resulted from processing procedure, but it still has low conductivity and has disadvantage of difficult expecting its enhancement.

[0018] As mentioned above, to be applicable conductive polymer into IC and material for shielding electronic wave or for preventing static electricity, the polymer has needed improvement of conductivity, solubility and physical/mechanical properties. Especially, development of photo-sensitive polyanilie/polypyrrole derivatives having influenced transparency without particles about several μm or aggregates, high-sensitivity and patternability and of doping technique have been needed to manufacture IC through photo-lithography techniques urgently. But most conductive polymers co-exist in various chain forms because they linked consequently through firm conjugated double bonds and they lack spinning or fluidity of inter-linkage. It is preferable the polymer chain has trans-formed linear structure to cis-formed linked structure but it is difficult to producing trans-formed structure in real processing. It is the reason of difficulty to synthesizing polyaniline with high metallic conductivity that polyaniline having crystalline chain structure arrayed regularly conductive polymer chain form like a rod is difficult to form.

[0019] Also, it needs not only conductivity also low light absorbance to exposed light wave and remarkable soluble difference to pattern solution according to doping or not by selective exposed light for these polymers to be directly used in manufacturing the IC.

DISCLOSURE OF INVENTION

[0020] It is a principal object of the present invention to provide a conductive polymer with enhanced conductivity and patternability in photo fine-processing(lithography) and composition containing the polymer. As mentioned above, on adding photo-acid generating reagent into polymer substituted with acid labile functional group as protection group, produced acid can induce de-protection reaction and result in accompanying chemical amplification reaction. According to the principle, the present inventors can produce the polymer with influenced conductivity and patternability by inducing acid labile functional group into conductive polymer to induce linear chain form of backbone of the polymer and to enable to dope effectively.

[0021] Accordingly the present invention is to provide a conductive polymer composition having high solubility, conductivity and physical/mechanical properties and having enhanced transparency required in photo fine-processing techniques, high-sensitivity, adhesion and patternability compared to conventional polyaniline/polypyrrole composition. As a result the composition in the present invention is applicable to various usages such as IC and material for shielding electronic wave or for preventing static electricity.

[0022] In a first aspect, the present invention is to provide a conductive polymer substituted with acid functional group comprising amine functional group and acid labile functional group, as protection group, substituted for amine functional group of the polymer.

[0023] It is desirable that the conductive polymer is selected from the group consisting of polyaniline or polypyrrole regardless of substituents and the polyaniline is emeraldine salt form. And it is desirable that the acid labile functional group is substituted to amine functional group of the polymer with a ratio 1%˜99% by number. It is desirable that the functional group is selected from tert-butyloxycarbonyl(t-BOC) and tetrahydropyran(THP) and the polymer substituted with the functional group has a number average molecular weight of 1000 to 100,000.

[0024] In another aspect, the present invention is to provide a conductive polymer composition comprising:

[0025] An electrically conductive polymer containing amine functional group and substituted acid labile group as protection group for the amine group; and

[0026] A soluble self-orienting material of monomer form, which mixed with said polymer at the ratio of 10:90 to 90:10 by weight, comprises General formula 1 below.

[0027] (Wherein p is an integer of 1 and more; A1 is an aromatic ring; X1 and X2 are independently selected from the group consisting of—SO₂OH, —COOH, —C02 and □S03; Z1 and Z2 are independently selected from hydrophilic group, hydrophobic group or amphiphilic group).

[0028] In another aspect, the present invention also provides a conductive polymer composition comprising:

[0029] An electrically conductive polymer containing amine functional group and substituted acid labile group as protection group for the amine group; and

[0030] A soluble self-orienting material of metal salt form, which mixed with said polymer at the ratio of 10:90 to 90:10 by weight, comprises General formula 2 below.

[0031] (Wherein q is an integer of 1 or more; A1, X1, X2, Z1, and Z3 are defined in general formula 1; M is alkali metal or transition metal of cation form)

[0032] In another aspect, the present invention also provides a conductive polymer composition comprising:

[0033] An electrically conductive polymer containing amine functional group and substituted acid labile group as protection group for the amine group; and

[0034] A soluble self-orienting material of whole-aromatic polymer form, which mixed with the polymer at the ratio of 10:90 to 90:10 by weight, comprises General formula 3 below.

[0035] (Wherein r is an integer of 1 or more; A1 is defined in general formula 1; X1′ and X2′ are independently selected from the group consisting of —SO₂, —CO; X3 and X4 are independently selected from the group consisting of—O— and —NR, wherein R is side chain independently selected from the group consisting of —H, —SO₃H —CO₂H, —(CH₂)_(n)SO₃H, —(CH₂)_(n)CO₂H or -tert-butyloxycarbonyl; Z1 to Z4 are independently selected from hydrophilic group, hydrophobic group or amphiphilic group)

[0036] The composition may contain dopant material 1-50% by weight on the basis of the composition consisted of polymer and soluble self-orienting material. It is desirable the dopant material is selected from inorganic or organic photo-acid generating reagent regardless of photo-acid generating reagent. Also it is more desirable the inorganic photo-acid generating reagent is triphenylsulfoniumhexafluoroanthimonate and organic photo-acid generating reagent trifluorosulfonyloxynorvoneneimide.

[0037] As above mentioned, on adding photo-acid generating reagent into the conductive polymer composition of the present invention, produced acid induce deprotection reaction to accompany chemical amplification reaction.

[0038] In the conductive polymer composition, it is desirable that the acid labile functional group is 5-10% by weight on the basis of total composition.

[0039] Also the composition further comprises thermoplastic resin, thermostatic resin and complex thereof for using it as processing manufacture. In using for processing manufacture, it is desirable that added polymer is 10˜90% by weight on the basis of total composition.

[0040] Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments.

DETAILED DESCRIPTION OF INVENTION

[0041] The present invention relates to composition (hereinafter referred as ACP composition) comprises:

[0042] A conductive polymers substituted with acid labile functional group as protection group (hereinafter referred as ACP); and

[0043] Soluble self-orienting materials (hereinafter referred as SOM), as an additive for enhancing electrical, optical and mechanical properties of the ACP, developed by the applicants.

[0044] The conductive polymer may be selected from polyaniline or polypyrrole with amine functional group. The acid labile functional group may be selected from t-BOC or THP and be substituted for amine functional group once or twice per repeat unit of the polymer. That is, it is desirable that the acid labile functional group is 1˜99% by number on total amine functional group of the polymer. The SOM, as an additive material for improving conductivity, transparency and adhesive property of the polymer, consisting of the ACP composition can be selected from SOM of monomer form shown General Formula 1 below, SOM of metal salt form shown General Formula 2 and whole-aromatic polymer form shown General Formula 3.

[0045] Wherein p, q, or r in General formula 1, 2, 3 respectively is an integer 1 or more; A1 , A2 is an aromatic ring; X1 and X2 are functional group independently selected from —SO₂0H, —COOH, —CO2 or —SO3; M in General formula is alkali metal or transitional metal of cation form; X′ and X2′ in General formula 3 are independently selected from —SO2—or —CO—; X3 or X4 in General formula 3 are functional group independently selected from —O, —NR—, where in R is a side chain selected from —H, —COOH, —(CH₂)nSO₃H, —(CH₂)_(n)COOH, and tert-butyloxycarbonyl; and Z1 to Z4 are independently selected from hydrophilic group, hydrophobic group or amphiphilic group.

[0046] It is desirable that A1 is independently elected from phenyl, naphthyl, biphenyl (Φ-Φ; Φ=C₆H₅), benzophenone (Φ-CO-Φ), benzanilide (Φ-CONH-Φ), phenylether (Φ-O-Φ), phenylsulfide (Φ-S-Φ), phenylsulfone (Φ-SO₂-Φ) and phenylsulfoneamide (Φ-SO₂NH-Φ) and that A2 is independently from phenyl, naphthyl and biphenyl.

[0047] Also Z1 to Z4 comprise —H and at least one of them is side chain with length of 2-30 containing carbon, nitrogen, sulfur or oxygen. It is desirable that the side chains are alkyl, alkenyl, alkynyl or alicyclic derivatives selected from the group consisting of —(CH₂)_(n)CH₃, —O—(CH₂)_(n)CH₃, —O(CH₂)_(n)OCH₃, (OCH₂CH₂)_(n),OCH₃ (wherein n is an integer of 1-24). It is more desirable that terminal end of the side chain consist of sulfonic acid(—SO₃H), carboxylic acid(—CO₂H), benzene sulfonic acid(—OC₆H₄SO₃H), benzene carboxylic acid(-OC₆H₄CO₂H), azacrownether, carbazole and thiol(—SH).

[0048] It is desirable that M in general formula 2 is independently selected from Li⁺, Na⁺, K⁺, Cu²⁺, Zn²⁺, Cd²⁺, Mg²⁺, Pb²⁺, Mn²⁺, Fe² ⁺Ca²⁺, Fe³⁺, Ti⁴⁺, Zr⁴⁺and Mn⁷⁺and that the SOM with whole aromatic polymer form is linear copolymer material comprising at least one of poly-p-phenyleneterephthalate, poly-p-phenyleneterephthalamide, poly-2,6-naphthaleneterephthalate, poly-2,6-naphthaleneterephthalamide in 1˜30% by molar ratio.

[0049] The SOM has no limit of molecular weight and may be mixed in composition of 1˜95% by weight according to requiring electrical conductivity. For example, on the number average molecular weight of the conductive polymer being less than 5,000, it can enhance mechanical property and electrical conductivity of the composition by raising the molecular weight of SOM more than 0.2 g/dl(NMP) of intrinsic viscosity and by increasing contents of SOM to 85% by weight. On the other hand, if number average molecular weight of the conductive polymer is more than 10,000, molecular weight or contents of SOM can be lower to 5% within the range of mechanical, physical properties. Accordingly, the ACP has number average molecular weight of 1000-100,000. Also the ACP composition may further comprise dopant materials, which can be used to photo-acid generating agent with property of generating acid by light.

[0050] Conventionally photo-acid generating agent has disadvantage of insolubility within conductive polymer, ACP composition of the present invention comprises SOM which play a role as enhancing solubility of photo-acid generating agent in conductive polymer. As a result, it can apply broadly the conductive polymer to photo fine-processing technique by adding photo-acid generating agents into the ACP composition. That is, on irradiating light into ACP composition containing photo-acid generating agent, it can achieve photo fine-processing techniques less than 0.35 μm and has electrical conductivity more than 100 S/cm, which is at least 10 times as high electrical conductivity as conventional polyaniline. Therefore, the ACP composition of the present invention can be used for photo-sensitive materials with various utilities such as conductive film, fiber, coating, electrode or organic semiconductor. However, it is desirable that the composition has contents of ACP at least 15% by weight, more WO 02/077070 PCT/KRO2/00312 desirably 50-85% by weight, to have more electrical conductivity than conventional conductive polymers.

[0051] In connected with the mentioned above, on comparing the electrical conductivity of film form composition sample, which is mixed with ACP and SOM of polymer form of 80:20 by weight and doped with another SOM containing strong acid such as sulfonic acid, with that of ACP sample not containing SOM, they showed 150 S/cm and 3 S/cm, respectively. So the sample doped with the SOM had approximately 50 times as high electrical conductivity as sample not treated with the SOM. However, if the contents of SOM with polymer and monomer form is more than 30% by weight on the basis of total ACP composition, the electrical conductivity decrease. It is very important to adjust contents of SOM in ACP composition with related to conductivity.

[0052] Generally, conductive polymer can be used to antistatic materials, static discharge materials or EMI shielding materials, battery electrode, semiconductor and solar battery in accordance with electrical conductivity of 10⁻¹³˜10⁻⁷ S/cm, 10⁻˜10⁻² S/cm or more than 1 S/cm, respectively. The conductive polymer of the present invention has electrical conductivity in the range of 10-8 to 10 S/cm in proportion to the contents of SOM and doping method. Accordingly, the polymer of the present invention can be applied to more broad usage such as transparent electrode, anti-corrosion, UV absorbent, etch mask layer for lithography of conventional semiconductor processing.

[0053] Dopants such as well known any inorganic or organic acid may be used in the ACP composition of the present invention to improve electrical conductivity and the conductivity can be influenced in accordance with conjugate bases and acidic salts. The dopant material may be polyphenylalkylamidesulfonic acid, hydrochloric acid or camphorsulfonic acid.

[0054] For example, on manufacturing the ACP composition mixed with SOM comprising polyphenylalkylamidesulfonic acid as dopant into the ACP and polyalkylamide with polymer form, it can enhance not only electrical conductivity of the ACP composition also processability, mechanical properties and stability of the conductivity. In this case, the SOM adding into ACP composition can be used independently or compositely according to the function of dopants. In case of using the SOM compositely, if the SOM has intrinsic viscosity (0.1 g/dL, NMP) of at least 0.2 g/dL and occupies contents with more than 10% by weight, the contents of additional SOM can be lower. Also in case ACP composition of the present invention comprising photo-acid generating agents, additional dopants may not be used. However, dopnats can be used for improving the electrical conductivity of the patternable polymers through photo fine-processing procedure after irradiating lights.

[0055] In case of using the photo-acid generating agent as dopant, its effect can be the greatest by raising the contents of the agent. Photo-acid generating agent in the present invention may be inorganic or organic material independently or compositely. The contents of photo-acid generating agent added into the ACP composition are regulated in accordance with the degree of substitution of acid labile functional group such as the t-BOC. It is particularly desirable that the agent is used in 5-15% by weight on the basis of total weight corresponding to mole number of acid labile in the conductive polymer.

[0056] The representative inorganic or organic photo-acid generating agent is TPSFPA or trifluorosulfonyloxynorborneneimide (TFSBI), respectively. The TPSFPA has a function of deprotection rather than as dopant because of low solubility and thereby difficulty of adding more than 3% by weight. On the other hand, TFSBI has functions of deprotection and as dopant because of enhanced solubility and thereby adding to 15% by weight. On irradiating the composition adding the TFSBI in light source with a wavelength of 345 nm or 436 nm, there happened deprotection reaction of the acid labile functional group by produced trifluorosulfonic acid. Deprotected t-BOC functional group decomposed into CO2 and t-BOC cation, which further decomposed into isobutylene and proton. t-BOC functional group is taken apart continuously by deprotection reaction resulted from chemical amplifying reaction by produced proton and trifluorosulfonic acid. Accordingly on completing the irradiation, the protection groups are decomposed to vanish and the ACP was doped to have high electrical conductivity.

[0057] In case of using polymer responding quantitatively to amine group per repeating unit, the substitution ratio of protection group to amine group existed in the ACP composition are measured high. On the other hand, if acid labile functional group is too much substituted in fine-processing procedure for being used in IC manufacture, the group may be soluble in patterning solution before being deprotected. Consequently, it is desirable that the contents of the functional group is 5˜10% by weight, that is, 50% substituted for every two amine functional group of repeating unit.

[0058] However, in case of doping polyaniline with HCl, it is known that the composition has maximum electrical conductivity in no more than 20% doping ratio (percentage), which is defined by [C1]/[N, total number]×100 and that it has reduced conductivity on overdoping of more than 50% of doping ratio (Chiang, MacDiarmid Synt. Met. 13, 193-205, 1986).

[0059] It is very important for the ACP composition of the present invention to maintain regulated doping ratio in inducing acid labile functional group. It is the reason that the contents of photo-acid generating agent are regulated in proportion to the acid labile functional group and that the agent play a role as inducing doping. Particularly, ACP substituted with acid labile functional group such as t-BOC or THP has extremely more excellent soluble property than conductive polymer not induced with protection group in ordinary organic solvent such as chloroform.

[0060] Also the ACP protection group has increased electrical conductivity to 250 S/cm, particularly more than 1000 S/cm on using bissulfonic acid monomer (General formula 9 below) as dopant, because it is induced self-doping resulted from selective deprotection process owing to chemical amplifying reaction by dopant and photo-acid generating agent.

[0061] Particularly according to the ACP composition of the present invention, it can be applied to directly manufacturing method of IC because it shows extremely selective soluble property to patterning solution before/after doping with regard to alkali solution/organic solvent patterning solution used generally in fine-processing procedure.

[0062] ACP composition of the present invention shows photo-absorbance of less than 0.45 per 1 μm thickness at 365 nm and 436 nm wavelength measured with UV spectroscopy. Therefore it can be applied to fine-processing technique using exposed light source of 365 nm (I-line) and 436 nm (G-line) as light source being used for IC manufacture.

[0063] The present invention can be applied to manufacture of electrode patterning of organic semiconductor, i.e. organic luminous body and Field Effects Transistors. Also, in manufacturing organic film, conventional organic solvent such as NMP or meta-cresol has complicated drying procedure and cause to reduced electrical conductivity resulted from basic and high boiling points. On the other hand, the conductive polymer of the present invention can be soluble in chloroform solvent with low boiling point and thereby have excellent adhesive property with regard to silicon wafer and glass matrix and excellent mechanical property such as being able to endure scratch.

[0064] Also, in case of manufacturing for use of conventional conductive polymer, if concentration of the polymer increase, gel-inhibitive must add to the polymer to prevent gelation resulted from hydrogen bond between amine functional groups in the polymer. However, the present invention need not add gel-inhibitive because of no hydrogen bond by function of the t-BOC functional group. Besides in case of the method for doping the polymer with monomolecular acid like sulfonic acid, the polymer complex shows insolubility and unmeltability to have poor processability and conductivity. As mentioned above, the protection group in the ACP polymer of the present invention is deprotected by chemical amplifying reaction to produce sulfonic acid, carboxylic acid or hydroxyl group and to induce self-doping method. Consequently the polymer has much too high electrical conductivity because of effective self-orienting by intermolecular hydrogen bond with SOM.

[0065] In a case of doping the composition of the present invention with nickel, aluminum, copper, steel, zinc, cobalt, lead, chrome, niobium, nobelium, silver, tantalum, titanium, zirconium and their alloy, the mixture is useful because the acid attached to side chains of the mixture form passivating anodic sites. That is to say, on doping the ACP composition on the upper part of metal material, polyaniline of the ACP is oxidized by deprotection reaction in accordance with acidic condition of the acid labile protection group. As a result the ACP functions as oxidizing agent to oxidizing reaction with metal and therefore the ACP is desirable for anti-corrosion material because it form passivating anodic site on the surface of the metal.

BEST MODE FOR CARRYING OUT THE INVENTION

[0066] To begin, we describe briefly general method for measuring electrical conductivity to measure the conductivity of manufactured material of the Example below.

[0067] <Method to measure electrical conductivity>

[0068] Electrical conductivity is measured by four-line probe method in room temperature with a relative humidity 50%. We used carbon paste for contacting gold wired electrode generally used with thickness of 1˜10 μim, and measured electrical current (i), two external electrodes and voltage (v) from filmic sample (thickness: t, width: w) with a thickness of 1˜10 μm and electrical conductivity with regard to distance (d) between two internal electrode with Keithley conductivity measurement apparatus. Electrical conductivity was calculated by below formula and unit of electrical conductivity is by Siemen/cm or S/cm.

Electrical conductivity=(1×i)/(w×t×v)

[0069] To certify whether the samples have uniform electrical conductivity, after fabricating samples, the conductivity was measured by Van der Pauw method, which is standard four points probe). The measure result shows uniform conductivity within 5% and no ununiformity on the film surface. All samples were dried in vacuum-drier to reduce the electrical conductivity increase by remained solvent and relative humidity was maintained at 50%.

[0070] Hereinafter, we describe in detail with regard to manufacturing method for ACP/ACP composition and method for forming fine patterning in the Example. In Example below, the polymer material is ACP or ACP composition of the present invention.

EXAMPLE 1

[0071] Example 1 is with regard to process for synthesizing t-BOC polyaniline and THP polyaniline.

[0072] Polyaniline was synthesized by MacDiarmid method (MacDiarmid et al. Conducting Polymers Ed. by Alcacer, Dordrecht, 105, 1987). Into Erlenmeyer flask was placed distilled, purified aniline 10 ml and 1M HCl solution 600 ml and solution of ammonium peroxide sulfate ((NH₄)₂S_(2O) ₈) 5.6 g dissolved in 1 M HCL 200 ml was added into the flask with stirring for 15 min. 2 hr. After filtering the obtained precipitate with filtering paper, the precipitate are washed with 1 M ammonium hydroxide 100 ml solution, transferred to 0.1 M ammonium hydroxide 500 ml solution, stirred for 20 hours, filtrated and dried with vacuum pump for 48 hrs to give polyaniline emeraldine base 1.5g. After dissolving the emeraldine base 1.0 g (5.5×10⁻³ mol) and di-tert-butyldicarbonate (D-t-BOC) 4.8 g (2.2×10-2 mol) in NMP 50 ml, pyridine 10 ml was added into the solution with stirring at 75° C. for 3 hrs. After filtering the reaction product by precipitating in excessive water and washing the product in composite solution of water/methanol with 1:1, the purified t-BOC polyaniline 1.3 g was obtained.

[0073] The substitution degree of the polyaniline per repeating unit can be regulated as follow. Mono-substituted t-BOC polyaniline, shown in General formula 5 below, out of two amino group per repeating unit shown in General formula 4 below and di-substituted t-BOC polyaniline, shown in General formula 6, out of two amino group per repeating unit shown in General formula 4 can be synthesized quantitatively by reacting D-t-BOC with the emeraldine base in molar ratio of 2:1 and 4: 1, respectively.

[0074] (Wherein x and y are positive integer, x is more than y.)

[0075] (Wherein R1 is t-BOC or THP; x and y are positive integer, x is more than y.)

[0076] (Wherein R1 is t-BOC or THP; x and y are positive integer, x is more than y.)

[0077] Also, conductive polymer substituted with THP was synthesized as follow. After dissolving polyaniline emeraldine base 1 g and dihydropyran (DHP) 0.93 g (1.1×10-2 mol) in NMP 50 ml, p-toluene sulfonic acid catalyst 30mg was added and the solution was reacted at 25° C. for 14 hours to synthesize THP-polyaniline.

[0078] On measuring absorbance by UV spectroscopy, the t-BOC substituted polymer shows typical t-BOC group absorbance band of 2900, 1720, 1690, 1300, 1100 cm-1 and the THP substituted polymer shows typical THP group absorbance band of 2900, 1350, 1100 cm-1. Therefore we identified that the polymer was substituted with acid labile functional group. On analyzing the substituted polymer with DSC (Differential Scanning Calorimeter) and TGA (Thermo Gravimetric Analyzer), the polymer shows glass transition point and pyrolysis point at 150° C. influenced from t-BOC group. The polymer has number average molecular weight of 10,000 by GPC (Gel Permeation Chromatography).

[0079] The substituted polymer contains acid labile functional group at 5˜15% by weight, most preferably 6-10% by weight with mono-substituted.

[0080] The conductive polymer has favorable characteristic as film material and shows relatively low photo-absorbance of less than 0.5 per 1 μm measured by UV spectroscopy at 365 nm, 436 mm. So the polymer can be applied to photosensitive polymer using exposed light source of I-line and G-line.

[0081] Before deprotection reaction, the ACP of the present invention is well soluble in organic solvent such as cyclohexanone and anisole. On the other hand after deprotection, it shows insolubility. That is, the solubility of the polymer changed drastically in proportion to polarity change in accordance with deprotection. Accordingly on irradiating light selectively by using this property, the polymer can be used to photosensitive materials capable of formation of fine patterning.

EXAMPLE 2

[0082] Example 2 is with regard to process for synthesizing t-BOC polypyrrole or THP polypyrrole polymers.

[0083] Polypyrrole 1.0 g was obtained by vacuum drying 5% polypyrrole aqueous solution (Aldrich co.). After dissolving the obtained polypyrrole 1.0 g and D-t-BOC 2.4g (1.1×10-2 mol) in NMP 50 ml, pyridine 10 mg was added and the solution was stirred at 75° C. for 24 hrs.

[0084] After filtering the reaction product by precipitating in excessive water and washing the product in composite solution of water and methanol of 1:1, the purified t-BOC polypyrrole 2.5g(45% yield) was obtained. Conductive polymer substituted with THP was synthesized by using the synthesis process illustrated in Example 1 above. Obtained polymer, shown in General formula 7, shows typical vibrating absorbance band of carbonyl group of t-BOC group and of C-O group of THP group by UV spectroscopy to identify the polymer substituted with acid labile functional group. The polymer has number average molecular weight, measured by GPC, of 12,000.

[0085] (Wherein n is positive integer; R1 or R2 is t-BOC or THP.)

[0086] Thermal analysis showed that acid labile functional group of the present invention was contained 5˜40% by weight on the basis of total polymer. Particularly, on the contents of the group being 6˜15% by weight the polymer showed the best electrical conductivity. Every conductive polymer shows favorable film formability and relative low light-absorbance of less than 0.5 per 1 μm, measured by UV spectroscopy, at 365 nm and 436 nm. Consequently, the polymer was verified to be adequate for application of photosensitive polymer using exposed-light source of I-line and G-line.

[0087] Before deprotection reaction, the photosensitive material of the present invention is well soluble in organic solvent such as cyclohexanone and anisole. On the other hand after deprotection, it shows insolubility. So, we identified the polarity change by deprotection to make the solubility of the polymer change drastically.

[0088] The conductive polymer of the present invention is selected from the substituted/non-substituted polyaniline or polypyrrole, and the polyaniline is emeraldine form.

EXAMPLE 3

[0089] Example 3 is with regard to production for primary t-BOC polyaniline composition and process for manufacturing thin-film using the composition.

[0090] Primary conductive polymer composition was produced by mixing t-BOC polyaniline (70% by weight) with polyalklyamide (30% by weight), shown in General formula 8 below, as SOM of polymer form. The composition (blend compound) as fundamental material was dissolved in composite solvent composed of meta-cresol and chloroform of 50:50 and by using ultrasonic syringe the composition of 12% by weight on the basis of total solvent was dissolved. Adding photo-acid generating agent TPSFPA 3% or TFSBI 10%, respectively, on the basis of the dissolved basic material compound into the solution, the solution was filtrated on filter with size of 0.5 μm. After coating with spinning the filtered solution on glass and silicon wafer matrix at 500 rpm for 30 minutes and doping with spinning the solution at 1000 rpm, thin film with thickness of 1 μm was manufactured. Manufactured thin film was prebaked on the hot plate of 40° C. for 10 minutes and the solvent was volatilized b vacuum pump for 24 hrs. Thereby final thin film was manufactured.

[0091] The manufactured thin film used exposed-light source of 248 nm wavelength and thin film treated with sulfonic acid monomer, which is shown in General formula 9 below, had electrical conductivity of 145 S/cm.

EXAMPLE 4

[0092] Example 4 is with regard to production for secondary t-BOC polyaniline composition and process for manufacturing thin-film using the composition.

[0093] Secondary conductive polymer composition was produced by mixing t-BOC polyaniline (50% by weight) with polyalkylamide (30% by weight) and polyphenoxyalkylmaidesulfinic acid, shown in General formula 10 below, as SOM of whole aromatic ring form. The composition as fundamental material was dissolved in composite solvent composed of meta-cresol and chloroform of 50:50 and by using ultrasonic syringe the composition of 15% by weight on the basis of total solvent was dissolved. And then the solution was filtrated through filter with size of 0.5 am. After coating with spinning the filtered solution on glass and silicon wafer matrix at 500 rpm for 30 minutes and doping with spinning the solution at 1000 rpm, thin film with thickness of 1 μm was manufactured. Manufactured thin film was prebaked on the hot plate of 80° C. for 10 minutes and the solvent was volatilized b vacuum pump for 24 hrs. Thereby final thin film was manufactured.

[0094] On analyzing the obtained deprotection polymer, it was identified to vanish carbonyl functional group, which is t-BOC protection group and to exist DNH band with ammonium ion form doped by proton acid induced from t-BOC protection group and added polyphenoxyalkylamidesulfonic acid. The then film had electrical conductivity of 78 S/cm.

EXAMPLE 5

[0095] Example 5 is with regard to process for making fiber by using the secondary t-BOC polyaniline composition.

[0096] To make fiber, tip of capillary tube manufactured by applying electro spinning had diameter of 0.5 mm and thereby induced perpendicular injection. Collection apparatus for injected polymer fiber had diameter of 6cm with cylinder form and was rotated at 3000 rpm. Cathode of power was connected to tungsten wire in the capillary tube and anode was connected to collection apparatus. In using electro-spin apparatus, after impressing high voltage of 10 KV, considering the viscosity of the filtrated composition and fixing the distance between the collection apparatus of the tube, then the electro-spin apparatus was rotated at 3000 rpm and thereby fiber of light green color with diameter of 12 μm was obtained. After cutting one strand of the fiber to 1 cm and fixing the both ends of the strand with carbon paste, it showed electrical conductivity of 35 S/cm by 2 points probe method.

[0097] In addition to the fiber, in case of using the ACP composition for usage of processing manufacture such as film, coating and the like, the composition may further comprise thermoplastic resin, thermosetting resin or complex thereof. The thermoplastic resin or thermosetting resin is polymer with excellent adhesive property such as polymethylmethacrylate, polyvinylpyrrolydinonone, polyphenyloxide, polycarbonate, polyamide, polyester, polyacrylonitrile, polyacrylonitrile-butadiene-styrene tricopolymer, polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyphenylene sulfide, polyimide or epoxy resin. Preferably, the polymer with adhesive property was added 10˜90% by weight on the basis of ACP composition and more preferably 10˜50% by weight.

EXAMPLE 6

[0098] Example 6 is with regard to process for forming fine patterning by using primary t-BOC polyaniline composition.

[0099] The thin film of the composition in Example 3 was exposed with exposure apparatus of 365 nm and 436 nm, it was post-exposure baked at 100° C. for 10 minutes and was dipping developed in TMAH alkali aqueous solution (2.38%) or cyclohexanone solvent for 60 seconds. Thereby exposed part or unexposed part is selectively dissolved to form fine patterning. On analyzing the obtained deprotection polymer by the thermochenical reaction with IR spectroscopy, it was identified to vanish carbonyl functional group, which is t-BOC protection group, and to exist □NH band with ammonium ion form doped by proton acid induced from t-BOC protection group and trifluorosulfonic acid produced from photo-acid generating agent.

[0100] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Industrial Applicability

[0101] As mentioned above, the ACP and ACP composition of the present invention show much high solubility, conductivity, physical or mechanical property and have improved transparency, high-sensitivity, adhesive property and patternability required for photo-fine processing technique compared with the conventional polyaniline/polypyrrole composition. Accordingly the ACP and ACP composition can be applied to IC, material for shielding electronic wave, material for preventing static electricity and the like.

[0102] Besides the ACP and ACP composition have at least 10 times high electrical conductivity than conventional polyaniline, maximum 102

[0103] S/cm, to be applicable to various photosensitive materials such as conductive film, fiber, coatings, electrode, organic semiconductor and the like. 

What is claimed is:
 1. A conductive polymer substituted with acid labile functional group, the conductive polymer comprising: An amine functional group; and An acid labile functional group as a protection group substituted to amine functional group of the conductive polymer.
 2. A conductive polymer substituted with acid labile functional group according to claim 1, wherein the acid labile functional group substitutes 1˜99% amine group to total amine group of the conductive polymer.
 3. A conductive polymer substituted with acid labile functional group according to claim 1, wherein the acid labile functional group is selected from the group consisting of t-BOC (tert-butyloxycarbonyl) and THP (tetrahydropyran).
 4. A conductive polymer substituted with acid labile functional group according to claim 1, wherein the conductive polymer has number average molecular weight of 1,000˜100,000.
 5. A conductive polymer substituted with acid labile functional group according to claim 1, wherein the conductive polymer comprises acid liable functional group substituted to polyaniline or polypyrrole.
 6. A conductive polymer substituted with acid labile functional group according to claim 5, wherein the polyaniline is emeraldine base form.
 7. A conductive polymer composition substituted with acid labile functional group, the conductive polymer composition comprising: An electrically conductive polymer comprising amine functional group and substituted acid labile group as protection group for the amine group; and A soluble self-orienting material of monomer form, which mixed with the polymer at the ratio of 10:90 to 90:10 by weight, comprises General formula 1 below.

(Wherein p is an integer of 1 and more; A1 is an aromatic ring; X1 and X2 are independently selected from the group consisting of —SO₂OH, —COOH, —CO₂ and □OSO₃; Z1 and Z2 are independently selected from hydrophilic group, hydrophobic group or amphiphilic group).
 8. A conductive polymer composition substituted with acid labile functional group, the conductive polymer composition comprising: An electrically conductive polymer containing amine functional group and substituted acid labile group as protection group for the amine group; and A soluble self-orienting material of metal salt form, which mixed with said polymer at the ratio of 10:90 to 90:10 by weight, comprises General formula 2 below.

(Wherein q is an integer of 1 or more; A1 is an aromatic ring; X1 and X2 are independently selected from the group consisting of —SO₂OH, —COOH, —CO₂ and OS0₃; Z1 and Z2 are independently selected from hydrophilic group, hydrophobic group or amphiphilic group; M is alkali metal or transition metal of cation form)
 9. A conductive polymer composition substituted with acid labile functional group, the conductive polymer composition comprising: An electrically conductive polymer containing amine functional group and substituted acid labile group as protection group for the amine group; and A soluble self-orienting material of whole-aromatic polymer form, which mixed with the polymer at the ratio of 10:90 to 90:10 by weight, comprises General formula 3 below.

(Wherein r is an integer of 1 or more; A1 and A2 are aromatic ring; X1′ and X2′ are independently selected from the group consisting of —SO₂, —CO; X3 and X4 are independently selected from the group consisting of—O— and —NR, wherein R is side chain independently selected from the group consisting of —H, —SO₃H, —CO₂H, —(CH₂)^(n)SO₃H, —(CH₂)_(n)CO₂H or -tert-butyloxycarbonyl; Z1 to Z4 are independently selected from hydrophilic group, hydrophobic group or amphiphilic group).
 10. A conductive polymer composition substituted with acid labile functional group according to any one of claims 7-9, wherein the conductive polymer composition substituted with acid labile functional group further comprising dopant material of 50% by weight on the basis of total weight of the conductive polymer and the soluble self-orienting material.
 11. A conductive polymer composition substituted with acid labile functional group according to claim 10, wherein the dopant material is independently selected from the group consisting of inorganic photo-acid generating agent, organic, and polymeric photo-acid generating agent.
 12. A conductive polymer composition substituted with acid labile functional group according to claim 11, wherein the inorganic photo-acid generating agent is triphenylsulfoniumhexafluoroantimonate.
 13. A conductive polymer composition substituted with acid labile functional group according to claim 11, wherein the organic photo-acid generating agent is trifluorosulfonyloxynorboneneimide.
 14. A conductive polymer composition substituted with acid labile functional group according to claim 11, wherein the polymeric photo-acid generating agent is poly(vinyl chloride).
 15. A conductive polymer composition substituted with acid labile functional group according to any one of claims 7-9, wherein the acid labile functional group is contained 5˜10% by weight on the basis of the total composition.
 16. A conductive polymer composition substituted with acid labile functional group according to any one of claims 7-9, wherein the composition further comprising thermoplastic resin, thermosetting resin or complex thereof for using it as processing manufacture.
 17. A conductive polymer composition substituted with acid labile functional group according to claim 15, wherein the further comprised thermoplastic resin, thermosetting resin or complex thereof is contained 10˜90% by weight on the basis of total composition 